RU2630146C1 - Multi-layer elastic layer materials with high strength and elasticity and methods of their obtaining - Google Patents

Abstract

FIELD: human vital needs satisfaction.

SUBSTANCE: invention relates to multilayer elastic laminates with increased strength and elasticity and methods for their preparation. The materials comprise a layer of thermoplastic elastomeric film and a plastic layer coextruded together, and an outer material laminated on the layer of the thermoplastic elastomeric film. Laminates are stretched, and then relaxed.

EFFECT: invention provides the creation of materials that have an increased overall strength and elasticity, and softness to the touch.

20 cl, 1 dwg, 3 tbl, 2 ex

Description

CROSS RELATIONS TO RELATED APPLICATIONS

[1] This application claims the priority of US patent application No. 14/475784, filed September 3, 2014, which is a partial continuation of US patent application No. 14/134755, filed December 19, 2013, US patent application No. 14/145500, filed December 31, 2013, and U.S. Patent Application No. 14/230741, filed March 31, 2014, all of which are incorporated herein by reference in their entirety.

FIELD OF TECHNOLOGY

The present disclosure relates to multilayer elastic layered materials with increased strength. In particular, the present disclosure relates to multilayer elastic laminate materials comprising a thermoplastic elastomeric film layer attached to an outer material and a plastic layer. The layers can be coextruded together, stretched and then relaxed, resulting in elastic layered materials with increased overall strength and elasticity. In some embodiments, the thermoplastic elastomeric film layer of the laminate materials comprises a combination of thermoplastic elastomers based on a polyolefin, styrene block copolymers and inorganic clay, and the plastic layer contains semi-crystalline or amorphous polymers. In some embodiments, the layers of the elastomeric film are substantially free of calcium carbonate.

Elastic layered materials have traditionally been used to provide convenience functions and a fairly snug fit in personal care products. For example, elastic laminated materials are used in side inserts, ear attachment zones and belts in diapers and underpants for training in a potty. Elastic layered materials currently on the market are made on the basis of an elastic polymer with a layered non-woven material as an outer coating. These nonwoven outer materials increase the mechanical strength of the laminate, since the elastic films themselves are generally not strong enough to prevent tearing in the event of excessive stretching of the laminate by the consumer. These nonwoven outer materials further prevent the sticking of the elastic film during high speed processing. In addition, nonwoven outer materials made from a synthetic polymer, for example polypropylene, polyethylene or other polyolefins, provide an improved fabric-like appearance of the laminate. These nonwoven outer materials, however, may account for more than 50% of the cost of elastic laminate materials.

Accordingly, an elastic laminate that provides an elastomeric film with increased strength, thereby shifting the load of the applied force from the outer materials, while providing a more flexible, softer and lower base weight outer material that can be adhesive or thermally bonded to other substrate materials, for example, to meet the requirements of high-speed conversion, is highly desirable. More specifically, in this area there is a need to obtain elastic layered materials having increased overall strength and elasticity, which ensures the transition of the curves of the dependence of strain on tension in the lower required region of deformation. In addition, it would be advantageous if elastic laminate materials could be made so as to have a tissue-like appearance similar to conventional nonwoven / elastic laminate materials using less nonwoven outer material or cellulosic outer material in order to reduce cost. Accordingly, the present disclosure relates to elastic laminate materials comprising an elastic layer and a plastic layer providing elastic laminate materials with increased strength and elasticity, and further with layered nonwoven material providing a softer fabric-like appearance and a sense of flexibility of conventional elastic laminate products. In some embodiments, the implementation of the elastic laminate has a more pronounced microstructured appearance on the surface of the plastic layer.

SHORT DESCRIPTION OF DISCLOSURE

Multilayer elastic layered materials are disclosed having improved mechanical strength, increased elasticity, and a tissue-like appearance. Laminates typically comprise a thermoplastic elastomeric film layer attached to the plastic layer and further attached to the outer material on the opposite side of the plastic layer. In particularly suitable embodiments, the outer material is cellulosic material. In other embodiments, the outer material may be a nonwoven. In some suitable embodiments, the first plastic layer is further located between two thermoplastic elastomeric films.

The elastomeric film layer has an elasticity that exceeds the elasticity of the plastic layer, in other words, the irreversible deformation of the elastomeric film layer is less than the irreversible deformation of the plastic layer. Layered materials are obtained by co-extrusion of an elastomeric film layer and a plastic layer and then stretching the layered material, followed by relaxation to obtain a layered material with the necessary surface characteristics and physical properties.

More specifically, the plastic layer of the laminate provides increased overall strength of the elastic laminate. In addition, the mechanical properties of the laminate are significantly improved by stretching and relaxing the laminate compared with the elastic laminate before stretching. These predominant mechanical properties are the result of an elongation of the plastic layer during the initial stretching and subsequent corrugation while relaxing the thermoplastic elastomeric film. If the laminate, including the corrugated plastic layer, again lengthens to the level of deformation during the initial stretching, as, for example, when using the layered material, the corrugated plastic layer only smoothes out and probably does not contribute to the tensile strength of the elastic laminate. That is, the tensile strength of the layered material to the level of deformation during the initial tension mainly prevails in the layer of the elastomeric film, so that the layered materials will maintain a low value of stress with elongation and less irreversible deformation after elongation, which is less than the deformation during the initial stretching. In the case of elongation, which is greater than at the level of deformation during the initial stretching of the plastic layer, the stress increases significantly due to the completely flattened plastic layer, as well as the orientation of the molecules of the plastic layer, which leads to a transition of the stress-strain curve to a smaller elongation with tensile strength at break 50-100% higher in comparison with a thermoplastic elastomeric film separately.

In addition, it was found that when manipulating the polymers used, the thickness of the plastic layers and the change in the degree of initial stretching, physical characteristics, such as the strength and elasticity of the laminate, can be controlled to provide a sufficient, and even necessary, design of the elastic laminate to the specific desired final product at a lower cost.

The outer material is further laminated onto the elastomeric film layer, and in particularly suitable embodiments, the cellulosic outer material (e.g., fabric) during the co-extrusion process. In some embodiments, the cellulosic outer material is a layer of weakened cellulosic outer material. It was unexpectedly discovered that by weakening the layer of cellulosic outer material of the elastic laminate before, during or after layering or bonding, and in particular a paper-based web of the fabric-elastomer fabric, the fabric becomes a fabric-like appearance and becomes soft to the touch, at least like traditional elastic non-woven layered materials. In some embodiments, weakening is achieved by embossing the cellulosic layer (s) external to the carrier using the provided surface pattern on the embossing rolls, the embossed cellulosic material layer being bonded to the elastic film by heat sealing, adhesive bonding, pressure bonding or other means and then the laminate is subjected to a characteristic stretching in one or both of the machine direction (MD) or the transverse direction (CD) to obtain the necessary surface properties. In other embodiments, attenuation is achieved by wetting the laminate containing cellulosic material after the layering process, and then stretching the wetted elastic laminate containing cellulosic material in one or both of the machining direction (MD) or the transverse direction (CD).

In the present disclosure, it was further found that the layering or bonding of a layer of cellulosic outer material with a thermoplastic elastomeric layer of a laminate by heat sealing, adhesive bonding or pressure bonding is the only required step to obtain tensile elastic laminate materials, but it alone is not sufficient to give them tissue-like characteristics surface. Weakening before layering and stretching after layering or weakening after layering and subsequent stretching can also be performed properly to obtain improved mechanical strength and a tissue-like appearance.

In other embodiments, the outer materials are different from nonwoven outer materials, including materials such as knitted carded webs, aerofoil webs, koform webs, waterjet webs, meltblown webs, spunbond webs, and combinations thereof known in the art. areas of non-woven fabrics.

Accordingly, in one aspect, the present disclosure relates to a multilayer elastic laminate. The elastic laminate contains: a first layer of a thermoplastic elastomeric film, characterized by irreversible deformation of less than 40% after 150% elongation, while the thermoplastic elastomeric film contains a polyolefin-based thermoplastic elastomer and a styrene block copolymer; the first plastic layer attached to the first surface of the thermoplastic elastomeric film layer, wherein the plastic layer is characterized by irreversible deformation exceeding the irreversible deformation of the elastomeric film layer by at least 50%, and the outer material is attached to the second surface of the thermoplastic elastomeric film layer.

In another aspect, the present disclosure relates to a method for producing an elastic laminate, the method comprising: coextruding at least one layer of a thermoplastic elastomeric film with at least one plastic layer on a first surface of at least one layer of a thermoplastic elastomeric film and laminating at least one outer material on the second surface of at least one layer of a thermoplastic elastomeric film to obtain an elastic layered material In this case, the first layer of the thermoplastic elastomeric film is characterized by an irreversible deformation of less than 40% after 150% elongation and contains a polyolefin-based thermoplastic elastomer, a styrene block copolymer and a strength improver, while the plastic layer is characterized by irreversible deformation exceeding the irreversible deformation of the elastomeric layer films of at least 50%, and wherein the plastic layer contains one of a semi-crystalline or amorphous polymer; stretching the elastic laminate in one or both of a machine direction or a transverse direction; and relaxation of the stretched elastic laminate.

DESCRIPTION OF GRAPHIC MATERIALS

In FIG. 1 shows a stress-strain curve for an elastomeric film layer, an elastic multilayer film made of an elastomeric film layer attached to a linear low density polyethylene (LLDPE) layer, and an elastic multilayer film made of an elastomeric film layer attached to an LLDPE layer, which It was originally stretched to 300% and 400% in the machine direction and left to relax.

DETAILED DESCRIPTION

Definitions

As used herein, the terms “polymer” and “polymer” generally include, without limitation, homopolymers, copolymers such as, for example, block, grafted, random and random copolymers, terpolymers, etc., and mixtures and modifications thereof. In addition, unless otherwise specifically limited, the term “polymer” includes all possible spatial configurations of a molecule. These configurations include, without limitation, isotactic, syndiotactic, and statistical symmetries.

As used herein, the term “nonwoven fabric” refers to a material made of synthetic polymer fibers, such as fibers of synthetic polyolefins (eg, polypropylene, polyethylene, polybutene and copolymers with carbon atoms of not more than C12, etc.) and / or natural fibers, such as cellulose fibers, bonded together by chemical, mechanical, heat treatment or solvent treatment. The "nonwoven fabric" also has the structure of individual fibers or threads that are interbedded, but without the possibility of identification, as in knitted fabric. "Non-woven material" is formed in the course of many processes, such as, for example, meltblown processes, spanbond processes, processes for obtaining a knitted carded web, the process of water-jet bonding.

“Knitted carded web” or “BCW” refers to a non-woven web formed by carding processes known to those skilled in the art, as well as described, for example, in US Pat. No. 4,488,928, incorporated herein by reference to the extent which it is compatible with this disclosure. In the carding process, you can use a mixture of staple fibers, binder fibers, and possibly other binding components, such as glue. These components form a voluminous ball, which is combed or otherwise processed to obtain an almost uniform base weight. This fabric is heated or otherwise treated to activate any adhesive component, which results in a combined, high-quality non-woven material.

As used herein, the term "coform" is a meltblown polymeric material to which fibers or other components can be added. In the most general sense, a coform can be obtained by having at least one meltblown extrusion head located near the trough through which other materials are added to the meltblown materials when forming a web. These “other materials” may be natural fibers, superabsorbent particles, natural polymer fibers (eg, from viscose) and / or synthetic polymer fibers (eg, polypropylene or polyester). The fibers may have a staple length. The coform material may contain cellulosic material in an amount of from about 10% by weight to about 80% by weight, such as, for example, from about 30% by weight to about 70% by weight. For example, in one embodiment, the coform material can be made so that it contains wood pulp fibers in an amount of from about 40% by weight to about 60% by weight.

The term “water-jet bonded web” in accordance with the present disclosure refers to a web that has been subjected to columnar jets of fluid that cause tangling of fibers. Water-jet fastening of the canvas, as a rule, increases the strength of the canvas. In one aspect, the pulp fibers can be bonded by water-jet bonding to form continuous filament material, such as a spunbond web. The web obtained by water-bonding, resulting in a nonwoven composite, may contain wood pulp fibers in an amount of from about 50% by weight to about 80% by weight, for example, in an amount of about 70% by weight. The above composite waterjet bonded webs are commercially available from Kimberly-Clark Corporation under the name HYDROKNIT®. Water-jet bonding is described, for example, in US patent No. 5389202 issued by Everhart.

As used herein, the term “meltblown process” is a non-woven fabric formation process in which molten polymer resins are extruded and stretched with heated air at high speed to form thin filaments. The threads are cooled and collected in the form of a canvas on a moving grate. The process is similar to the spunbond process, but the fibers obtained using the meltblown process are much thinner and are usually measured in micrometers.

Used in this document, the term "spunbond" represents the process of forming a non-woven fabric, in which the filaments were extruded, stretched and laid on a moving grid with the formation of the fabric. The term "spunbond" is often replaced by the term "spunblad", but in the industry, the terms "spunbond" or "obtained using spanbond technology" have traditionally been recognized to refer to a specific process of web formation. This is necessary to distinguish between this process of web formation and two other forms of spunlaid web formation, which are the meltblown and flash spinning processes.

As used herein, the term “spunbond / meltblown composite” is a layered composite defined by a multilayer fabric, which is usually made of various alternating layers of spunbond webs (“S”) and meltblown webs (“M”): SMS, SMMS, SSMMS and etc.

Canvases obtained by aerodynamic canvas forming are formed during molding by air, in which a fibrous non-woven layer is obtained. During dry-air laying, bundles of small fibers having typical lengths in the range of from about 3 to about 52 millimeters (mm) are separated and trapped in the supplied air, and then laid on the molding grate, usually by applying a vacuum. Randomly laid fibers are then bonded to each other using, for example, hot air or spray glue. The manufacture of air-laid non-woven composites is well defined in the literature and documented in the art. Examples include the DanWeb process described in US Pat. No. 4,640,810 to Laursen et al. and reassigned Scan Web of North America Inc .; the Kroyer process described in US Pat. No. 4,494,278 to Kroyer et al. and US Pat. No. 5,527,171 to Soerensen and assigned to Niro Separation upon presentation; the method according to US patent No. 4375448 issued by Appel and et al. and assigned to Kimberly-Clark Corporation, or other similar methods.

As used herein, the terms “weaken”, “weaken”, “weakened” refer to the loss of strength / stiffness within the outer material by loosening / tearing the fibrous material. Typically, exterior materials that are weakened using the methods described herein include weakened areas or gaps. For example, the outer material can be obtained or attached to the elastomeric film layer in such a way that grooves and / or fracture lines in the machine direction (MD) of the outer material are provided that can be seen when stretched in the transverse direction (CD).

Used in this document, the terms "machine direction" or MD refer to the direction along the length of the fabric in the direction in which it is made. The terms "transverse machine direction", "transverse direction", "transverse direction" or CD refer to the width direction of the woven material, i.e. to the direction usually perpendicular to the MD.

As used herein, the term “laminate” refers to a composite structure of two or more layers of sheet material that were bonded to each other during the bonding step, for example, by adhesive bonding, heat sealing, spot bonding, pressure bonding, extrusion coating coating, extrusion layering or ultrasonic bonding. In a particularly suitable embodiment, the layers are coextruded to form a multilayer elastic laminate.

As used herein, the term “elastomeric” and “elasticity” will be used interchangeably with the term “elastic” and refers to sheet material that can be extended by at least 25 percent of its length in a relaxed state and which, upon termination of the applied force, will restore at least at least 10 percent of its elongation. In general, it is desirable that the elastomeric material or composite be able to extend at least 100 percent, more preferably at least 300 percent, and even more preferably at least 400 percent of its length in a relaxed state, and recover at least 50 after the applied force has ceased to exist. percent of its elongation.

As used herein, the term “thermoplastic” refers to a polymer that can be melt processable.

As used herein, the term “breathable” refers to a water vapor permeable material. The rate of penetration of water vapor (WVTR) or the rate of penetration of moisture (MVTR) is measured in grams per square meter in 24 hours, and they are considered equivalent indicators of breathability. The term "breathable" desirably denote material which is permeable to water vapor having a minimum WVTR desirably about 100 g / m ^2/24 hours, more preferably greater than about 300 g / m ^2/24 hours, and even more preferably greater than about 1000 g / ^m2 / 24 hours.

In one aspect, the WVTR value for the fabric provides an indication of the comfort of wearing the fabric. Often, personal care products use breathable materials, preferably having higher values of WVTR, which more typically greater than about 1200 g / ^m2 / 24 hours, 1500 g / ^m2 / 24 hours, 1800 g / ^m2 / 24 hours or even exceed 2,000 g / m ^2/24 hours.

As used herein, the terms "impermeable" or "airtight" refer to any material that does not fall within the definition of "breathable" above.

As used herein, the term "permanent deformation" refers to the continued elongation of a material sample after elongation and recovery, i.e. after the material is pulled out and allowed to return to its original state during the test under cyclic loads.

As used herein, the term “irreversible deformation” is a percentage measure (%) of elongation at which stress becomes zero in the plot of% elongation versus stress. An ideal elastic material, such as a spring, will have zero irreversible deformation, since the contraction curve will pass through the origin. As defined herein, irreversible deformation is measured after 150% elongation of the material. For example, a sample of material with an initial working length of 1 inch, which is stretched to 150% elongation and relaxed back to a length of approximately 1.2 inches, is characterized by an irreversible deformation of 20%, as defined herein.

These measurements are carried out using a strip elongation test, which essentially meets the specifications in ASTM D5459-95. In particular, in this test, two clamps are used, each of which contains two jaws, with each jaw having an outer surface in contact with the sample. The clamps hold the material in the same plane, usually vertically, at a distance of 1 inch, and move the slider at a given stretching speed. The size of the sample is 4 inches by 3/8 inches (101.6 mm by 9.525 mm), and the outer surface of the sponge has a height of 1 inch and a width of 3 inches, and the speed of movement of the slide is 20 inches / min. The sample is fixed in the frame for electromechanical testing MTS (Mechanical Test Systems), which has the ability to collect data. The test is carried out at ambient conditions both in the transverse direction and in the machine direction (CD and MD). The results are recorded as an average of at least five samples.

The present disclosure generally relates to multilayer elastic laminate materials comprising a thermoplastic elastomeric film layer and a plastic layer, and further comprising an outer material attached to the elastomeric film layer. In some embodiments, the elastomeric film and plastic layers are coextruded together, stretched, and then relaxed, and the outer material is further laminated onto the elastomeric film layer during or after the coextrusion process or by applying the stretch bonding process, resulting in elastic laminate materials with increased overall strength and elasticity, and in addition, in some embodiments, improved tissue-like appearance of the outer surface. Accordingly, the elastic laminate materials of the present disclosure may provide stronger and more elastic areas in personal care products such as diapers, potty panties, bathing clothes, absorbent panties, adult incontinence products, and feminine hygiene products such as sanitary towels for women, napkins and daily pads.

Typically, the elastic laminate materials of the present disclosure comprise a thermoplastic elastomeric film layer attached to a plastic layer. In some embodiments, the laminate materials comprise more than one layer of a thermoplastic elastomeric film and / or more than one layer of plastic. For example, in some embodiments, the laminate comprises a first layer of thermoplastic elastomeric film attached to the first plastic layer and a second layer of thermoplastic elastomeric film attached to the first plastic layer opposite the first thermoplastic elastomeric film. In addition, in other embodiments, two separate layers of plastic may be between the layers of the thermoplastic elastomeric film or attached to them. It should be understood that more than two layers of plastic and / or more than two layers of a thermoplastic elastomeric film, for example three, four, five or even more layers of plastic and / or thermoplastic elastomeric film, can be used in laminated materials without deviating from the scope of the present disclosure.

Layers of a thermoplastic elastomeric film for use in the elastic laminate materials of the present disclosure have a base weight of from about 10 g / m ² to about 300 g / m ² , including from about 20 g / m ² to about 150 g / m ² and including from about 30 g / m ² to about 100 g / m ² .

Any variety of thermoplastic elastomeric polymers, such as elastomeric polyesters, elastomeric polyurethanes, elastomeric polyamides, elastomeric copolymers, elastomeric polyolefins, etc., can be used in the present disclosure.

In particularly suitable embodiments, the thermoplastic elastomeric film layer comprises a combination of thermoplastic elastomers based on a polyolefin and styrene block copolymers.

Examples of polyolefin-based thermoplastic elastomers suitable for use in elastomeric film layers include, but are not limited to, a crystalline polyolefin, for example a homopolymer or copolymer of an α-olefin with 1 to 20 carbon atoms, including 1 to 12 carbon atoms.

Examples of crystalline polyolefins include homopolymers and copolymers described below.

(1) Ethylene homopolymer.

An ethylene homopolymer can be obtained by any process at a low pressure of the medium and a process at a high pressure of the medium.

(2) Copolymers of ethylene and not more than 10 mol. % α-olefins other than ethylene or vinyl monomers such as vinyl acetate and ethyl acrylate; examples include a copolymer of ethylene and octene, available as Engage 8407 or Engage 8842 (Dow Chemical, Houston, Texas).

(3) Propylene homopolymer; examples include the impact resistant PP7035E4 polypropylene copolymer and the PP9574E6 random polypropylene copolymer (Exxon Mobil, Houston, TX).

(4) Statistical copolymers of propylene and not more than 10 mol. % α-olefins other than propylene.

(5) Block copolymers of propylene and not more than 30 mol. % α-olefins other than propylene.

(6) Homopolymer of 1-butene.

(7) Statistical copolymers of 1-butene and not more than 10 mol. % α-olefins other than 1-butene.

(8) Homopolymer of 4-methyl-1-pentene.

(9) Statistical copolymers of 4-methyl-1-pentene and not more than 20 mol. % α-olefins other than 4-methyl-1-pentene.

Examples of α-olefins include ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene and 1-octene.

Illustrative commercially available polyolefin-based thermoplastic elastomers for use in elastomeric film layers include VISTAMAXX ™ (polypropylene-based elastomer available from ExxonMobil Chemical, Houston, Texas), INFUSE ™ (olefin block copolymers available from Dow Chemical Company, Midland, MI) ), VERSIFY ™ (propylene-ethylene copolymers), for example VERSIFY ™ 4200 and VERSIFY ™ 4300 (Dow Chemical Company, Midland, MI), ENGAGE ™ (ethylene-octane copolymer available from Dow Chemical, Houston, Texas), as well as NOTIO 0040 and NOTIO 3560 (available from Mitsui Chemical (USA), New York, NY). In one particularly suitable embodiment, the polyolefin-based thermoplastic elastomer is VISTAMAXX ™ 6102FL.

In an alternative embodiment, the thermoplastic elastomer may be ester / ether based thermoplastic elastomers or thermoplastic polyurethanes, including PEBAX® elastomers, which are polyamide block copolymers (commercially available from Arkema, France).

Layers of a thermoplastic elastomeric film usually contain more than 50% by weight of a thermoplastic elastomer and, in particular, more than 50% by weight of a thermoplastic elastomer based on polyolefins, including more than 55% by weight, including more than 60% by weight, including more than 65% by weight, including more than 70% by weight, including more than 75% and including more than 80% by weight of thermoplastic elastomer. In suitable embodiments, the thermoplastic elastomer film layer contains 50% by weight of the thermoplastic elastomer. In still other suitable embodiments, the thermoplastic elastomeric film layer comprises about 62% by weight of the thermoplastic elastomer. In still other suitable embodiments, the thermoplastic elastomeric film layer comprises about 65% by weight of the thermoplastic elastomer. In other suitable embodiments, the thermoplastic elastomeric film layer contains about 82% by weight, or even about 83% by weight, or even about 90% by weight of the thermoplastic elastomer.

If the thermoplastic elastomer film layer contains polyolefin-based thermoplastic elastomers, the thermoplastic elastomer film layer may further comprise a styrene block copolymer. Surprisingly, the addition of styrene block copolymers has been found to improve the mechanical strength of the film. Given these improved functional and structural characteristics, the layers of the thermoplastic elastomeric film provide the opportunity to produce personal care products such as disposable diapers, potty training pants and the like, with improved comfort, durability and snug fit functions. More specifically, in some embodiments, layers of a thermoplastic elastomeric film with improved mechanical strength reduce the base weight since fewer external materials are used in the personal care product. In addition, the layers of the thermoplastic elastomeric film are characterized by improved permeability properties. As defined herein, “puncture resistance properties” generally refers to the resistance or stiffness of a film when the film layer resists tearing during use, such as, for example, the ability of a film layer to resist penetration by a user's finger.

Illustrative styrene block copolymers for use with thermoplastic elastomers include hydrogenated polyisoprene polymers such as styrene-ethylene propylene-styrene (SEPS), styrene-ethylene propylene-styrene-ethylene propylene (SEPSEP), hydrogenated polybutadiene polymers, such as styrene-ethylene-styrene-such as styrene-ethylene-butyrene-such as ), styrene-ethylene butylene-styrene-ethylene butylene (SEBSEB), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-isoprene-butadiene-styrene (SIBS), hydrogenated polyisoprene / butadiene such as butadiene styrene-ethylene-ethylene-propylene-styrene (SEEPS), and hydrogenated vinyl polyisoprene / hydrogenated polyisoprene / polystyrene triblock copolymers, such as the commercially available HYBRAR ™ 7311 (Kuraray America, Inc., Houston, Texas), and combinations thereof. Block copolymer configurations such as diblock, triblock, multiblock, star and radial are also provided in the present disclosure. In some cases, higher molecular weight block copolymers may be required. Block copolymers are available from Kraton Polymers U.S. LLC, Houston, Texas, under the names, for example, Kraton MD6716, Kraton D1102, Kraton SIBS D1102, Kraton D1184, Kraton FG1901 and Kraton FG1924, as well as from Septon Company of America, Pasadena, Texas, under the names Septon 8007, Septon V9827 and Septon 9618. Other possible suppliers of such polymers include Dynasol from Spain. In particular, the Kraton MD6716 SEBS triblock copolymer is particularly suitable for the present disclosure.

The layers of the thermoplastic elastomeric film as a whole can contain from about 15% to about 40% by weight of a styrene block copolymer, including about 30% by weight of a styrene block copolymer.

Surprisingly, it was found that the layers of a thermoplastic elastomeric film for use in the elastic laminate materials of the present disclosure have a tensile strength that is greater by 40% to about 100% than that of a thermoplastic elastomeric film layer without a styrene block copolymer. In some embodiments, the film layers have a tensile strength that is greater than about 50% to about 80% more than a thermoplastic elastomeric film layer without a styrene block copolymer.

In particularly suitable embodiments, to further improve the strength of the layers of the thermoplastic elastomeric film, the film layers may further comprise a strength improver. As defined herein, a “strength enhancer” refers to physically formulated superconcentrate or a mixture of organic polymers and up to 10% by weight of inorganic particles, which can enhance a mixture of a thermoplastic elastomer and a styrene block copolymer or make a layer of a thermoplastic elastomeric film more durable, which is expressed in an increase in tensile strength at break with a decrease in elongation at break without violating the properties of elasticity, expressed in hysteresis and permanent deformation p After 150% elongation.

Suitable strength enhancers include inorganic clays, and in suitable embodiments include, for example, polymer grade montmorillonites, which are high purity aluminosilicate minerals known as phyllosilicates. Montmorillonites have a leaf-like or lamellar structure. Although their dimensions in the directions of length and width can be measured in hundreds of nanometers, the thickness of the mineral is only one nanometer. As a result, the individual sheets have aspect ratios (length / width (d / w) or thickness / diameter (d / d)) ranging from about 200 to about 1000, and in particularly suitable embodiments, from about 200 to about 400.

In some embodiments, strength improvers are inorganic clay particles, such as, for example, Nanocor I.44P (available from Nanocor, Hoffman Estates, Illinois) having an average particle size of less than 20 microns in diameter, including from about 10 microns to about 15 microns in diameter, and in particularly suitable embodiments, about 13 microns in diameter. In other embodiments, strength enhancers are inorganic clay and polypropylene mixtures, such as, for example, a Nanocor PP masterbatch (available from Nanocor, Hoffman Estates, Illinois).

The layers of the thermoplastic elastomeric film as a whole can contain from about 2% to about 10% by weight of a strength improver, including from about 3% to about 8% by weight, including from about 3% to about 5% by weight strength enhancer.

The layers of the thermoplastic elastomeric film may further comprise means for improving technological properties and / or tackifiers associated with elastomeric polymers known in the film making industry.

In some embodiments, the layers of the thermoplastic elastomeric film may be substantially free of calcium carbonate. In this context, and unless otherwise indicated, the term "practically does not contain" means that the content of calcium carbonate in the layers of the thermoplastic elastomeric film is less than its functional amount, usually less than 1%, including less than 0.5%, including less than 0.1%, including less than 0.05%, including less than 0.015%, including less than 0.001%, and also including zero percent by total weight of the layer of thermoplastic elastomeric film.

Due to the fact that these layers of a thermoplastic elastomeric film practically do not contain filler particles, such as calcium carbonate, in some embodiments, the films are impermeable to air. However, it should be understood that in alternative embodiments, the implementation of the layers of the films can be obtained breathable.

The layers of the thermoplastic elastomeric film used in elastic layered materials are characterized by irreversible deformation after 150% elongation of less than 40%, including irreversible deformation after 150% elongation of less than 30%, including irreversible deformation after 150% elongation, component of less than 20%.

The elastic laminate materials of the present disclosure further comprise a plastic layer. The plastic layer of elastic laminated materials contains semi-crystalline or amorphous polymers. Suitable semi-crystalline polymers for use in plastic layers include a polyolefin, polyolefin-based copolymers, polyesters, and combinations thereof.

Accordingly, the plastic layers contain from about 5% by weight to about 50% by weight of a semi-crystalline or amorphous polymer, including from about 10% by weight to about 40% by weight of a semi-crystalline or amorphous polymer, including from about 15% by weight weight up to about 35% by weight of a semi-crystalline or amorphous polymer.

It should be understood that in order to ensure the predominant physical properties of the elastic laminate materials according to the present disclosure, the plastic layer should have a greater irreversible deformation than the thermoplastic elastomeric film layer of the elastic laminate. Accordingly, plastic layers for use in elastic laminate materials according to the present disclosure are characterized by irreversible deformation after 150% elongation of more than 50%, including more than 60%, including more than 70%, including more than 75%, including more 80%, including more than 85% and including more than 90%.

The multilayer elastic laminate materials further include an outer material attached to the thermoplastic elastomeric film layer. In one embodiment, the outer material is a non-woven outer material, for example, a knitted carded web, an aerodynamic canvas forming cloth, a koform web, a water-jet bonded web, a meltblown web, a spunbonded web, and combinations thereof commonly used in the field of elastic laminated materials.

In another embodiment, the outer material is a cellulosic material, and in particular a weakened cellulosic material. Weakened cellulosic material provides layered materials having an improved fabric-like appearance without the use of expensive non-woven outer materials. In one embodiment, the cellulosic material is a paper-based web because it provides essentially the ability to lift the elastic laminate and additionally the ability to absorb water. Accordingly, when considering cellulosic material throughout this application, it should be understood that the cellulosic material may suitably be a fabric, however, as an alternative, it may be any other cellulosic material known in the art.

The base weight of the cellulosic material as a whole can vary, such as, for example, from about 2 grams per square meter (g / m ² ) to 20 g / m ² , in some embodiments, from about 5 g / m ² to about 15 g / m ² and in some embodiments, from about 8 g / m ² to about 12 g / m ² . Lower base weight cellulosic materials may be preferred in some applications. For example, materials with lower base weights can provide even more significant cost savings without sacrificing performance.

Fibers suitable for the production of cellulosic material and, in particular, paper-based web material include any natural or synthetic cellulosic fibers, including, without limitation, non-wood fibers such as cotton, abacus, kenaf, sabai grass, linen, esparto, straw, jute, hemp, bagasse, milkweed fiber, bamboo fiber, algae fiber, corn straw fiber and pineapple leaf fiber; and wood fibers or wood pulp fibers, such as those obtained from deciduous and coniferous trees, including softwood fibers, such as kraft pulp fibers from northern and southern softwoods; Hardwood fibers such as eucalyptus, maple, birch and aspen. Wood pulp fibers can be obtained in high yield or low yield forms and can be cooked using any known method, including high yield kraft sulfite cooking methods and other known cooking methods.

In general, any method by which a fibrous web can be formed can be used to form a cellulosic material. For example, in the paper production method, creping, wet creping, double creping, embossing, wet pressing, air pressing, through drying with air, through drying with air creping, through drying with air without creping, air laying, coform techniques, as well as other steps known in the art.

Chemically treated natural cellulosic fibers, such as mercerized wood pulps, chemically strengthened or crosslinked fibers, or sulfonated fibers can be used. For good mechanical properties in the application of fibers from the paper manufacturing field, it may be desirable for the fibers to be relatively intact and substantially unpeeled or only slightly peeled. Since recycled fibers are possible, raw fibers are generally usable due to their mechanical properties and the absence of impurities. Mercerized fibers, regenerated cellulosic fibers, cellulose processed by microorganisms, and other cellulosic material or cellulose derivatives can be used. Suitable fibers from the papermaking industry may also include recycled fibers, crude fibers, or mixtures thereof. In certain embodiments, fibers having high volume and good compression properties may have a Canadian standard milling ratio of at least 200, more specifically at least 300, even more specifically at least 400, and most particularly at least 500.

Other fibers from the papermaking industry that can be used in the present disclosure include tearing paper fibers or recycled fibers and high yield fibers. High yield pulp fibers are those from the papermaking field that are produced using cooking methods that yield 65% or more, more specifically 75% or more, and even more specifically from about 75% to about 95%. The yield is the resulting amount of processed fibers, expressed as a percentage of the initial mass of wood. Using these cooking methods, bleached chemothermomechanical pulp (BCTMP), chemothermomechanical pulp (CTMP), thermomechanical pulp with pressure application (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), sulfite pulps with high yield and kraft pulps with high yield, all of which result in fibers with high levels of lignin. High yield fibers are well known for their strength in both dry and wet conditions compared to conventional chemically welded fibers.

In some suitable embodiments, in order to obtain tensile elastic layered materials with weakened regions, the cellulosic material should be weakened into a very thin structure (e.g., a weakened structure having a range of from about 0.125 mm to about 5 mm, including from about 0.125 mm to about 1 mm, including from about 0.25 mm to about 0.75 mm), so that the obtained modulus of elasticity and the thickness of the cellulosic material were three times less or even less than those of the layer ermoplastichnoy elastomeric film. This is equivalent to saying that the strain / stress energy within the film layer is at least one third of that in the cellulosic material, so that the film layer plays a major role in the process of deformation of the laminate, which minimizes or eliminates critical fracture and large gaps within (e.g., cellulosic) layer (s) of the surface of the elastic laminate.

In one embodiment, the cellulosic material can be weakened by embossing the material using any method known from the field of embossing and as further described, for example, as regards sheets of a paper based product disclosed in any of the following: US Pat. No. 4,514,345 to Johnson et al. . April 30, 1985; U.S. Patent No. 4,528,239 to Trokhan on July 9, 1985; US patent No. 5098522, issued March 24, 1992; U.S. Patent No. 5,260,171 to Smurkoski et al. November 9, 1993, U.S. Patent No. 5,275,700, issued to Trokhan on January 4, 1994; US patent No. 5328565 issued by Rasch et al. July 12, 1994; U.S. Patent No. 5,334,289 to Trokhan et al. August 2, 1994; US patent No. 5431786 issued by Rasch et al. July 11, 1995; U.S. Patent No. 5,496,624 to Steltjes, Jr. et al. March 5, 1996, US Patent No. 5,500,277 to Trokhan et al. March 19, 1996; U.S. Patent No. 5,514,523 to Trokhan et al. May 7, 1996; U.S. Patent No. 5,554,467 to Trokhan et al. September 10, 1996; U.S. Patent No. 5,566,724 to Trokhan et al. October 22, 1996; U.S. Patent No. 5,624,790 to Trokhan et al. April 29, 1997; U.S. Patent No. 5,628,876 to Ayers et al. May 13, 1997, the disclosures of which are incorporated herein by reference to the extent that they do not contradict the information set forth in this document. In particularly suitable embodiments, the cellulosic material is embossed using a metal shaft with a pattern opposite the smooth rubber roller to weaken the bonding between the fibers in certain areas and to provide the required strength of the cellulosic material. Embossing preliminarily weakens the cellulosic material, preliminarily weakened material is then completely weakened to provide the required surface properties by stretching the elastic laminate in one or both of MD or CD until elongation of at least 50%, including at least 100%, including at least 150% and including at least 200% or more.

Additional stretching of the elastic laminate, including cellulosic material, can be performed using any tensile means known from the field of laminate.

Typically, an embossed pattern in a cellulosic material can be made by any method known in the art, for example, patterns made by wire mesh, scatter patterns made by round pins, triangular pins, square pins, diamond pins, elliptical pins, rectangular pins or squared pins and combinations thereof. In addition, embossing provides embossed patterned cellulosic material having a range of from about 0.125 mm to about 5 mm, including from about 0.125 mm to about 1 mm, including from about 0.25 mm to about 0.75 mm. For example, embossing may be protrusions separated by intervals from about 0.125 mm to about 5 mm, including from about 0.125 mm to about 1 mm, including from about 0.25 mm to about 0.75 mm.

In still other embodiments, the cellulosic material can be weakened by wetting the material (alone or in combination with a thermoplastic elastomeric film and a plastic layer as an elastic laminate) before stretching the laminate, as described below. More specifically, wetting the cellulosic material weakens the hydrogen bonds, thereby providing tensile weakening of the cellulosic material and / or the elastic laminate in one or both of the MD or CD to an elongation of at least 50%, including at least 100% , including at least 150% and including at least 200% or more.

Any solvent known in the field of cellulosic materials can be used to wet the material. For example, in the methods of the present disclosure, solvents such as water or alcohol or combinations thereof can be used.

In general, when wetted, the cellulosic material is weakened by wetting to the extent that the cellulosic layer (s) contains (at) 30-150% moisture, or preferably 50% to 80% moisture.

Without tensile weakening, such as only by embossing or wetting the cellulosic material, the high strength cellulosic material will inhibit the process of deformation of the elastic laminate during stretching, which will result in a large critical gap, for example, more than 10% of the total surface area of the laminate with gaps of size greater than 1 mm (measured as the length of the gap in the direction of extension) when stretching the laminate to elongation of 50%, 100% and / or 150% in one or both of MD and CD. Uncontrolled breaking / tearing of the cellulosic material makes the laminate unattractive from an aesthetic point of view.

One skilled in the art should understand that since the above description of weakening and stretching refers to an outer material that is cellulosic material, the outer material may well be the non-woven outer material described above, and embossing and / or can be performed on the non-woven outer material. it can be weakened, as is known in the art, without departing from the essence and scope of the present disclosure.

To obtain elastic layered materials according to the present disclosure, the thermoplastic elastomeric film layer and the plastic layer are coextruded together and then the outer material is layered. Joint extrusion of materials can be carried out using any means of extrusion known in the field of layering.

Moreover, the layering of the outer material on the layer (s) of the elastomeric film of the elastic laminate can be performed using any known technique, for example, extrusion layering (described above), heat welding, ultrasonic welding, adhesive bonding, air bonding, calendering bonding and etc. To increase the resistance of the outer material on the elastomeric film layer, an extrusion lamination process is preferable since it provides an increase in the degree of contact between the molten film of the elastomeric film layer and the fibers of the outer material, resulting in better bonding of the outer material on the elastomeric film layer. For example, an extruded elastic laminate as well as an outer material on one or both sides of an elastomeric film layer can be passed together through a clip formed between two shafts, both or one of which are patterned or patternless (i.e., a smooth shaft) . The necessary temperature and pressure during layering can be varied depending on many factors, including, without limitation, the area of the joint with the pattern, the properties of polymers, the properties of the fibers of the outer material, etc.

In one particularly suitable embodiment, if the outer material is a nonwoven outer material other than a cellulosic woven material, then the outer material may be stretched with a layer of thermoplastic elastomeric film. For example, the outer material (one side or both) can be bonded to the layer of elastomeric film by means of heated clamping rolls, while the elastic laminate is stretched so that the outer material can collect and form “folds” between the places where it binds a layer of elastomeric film when it is retracted. This stretch bonding process will activate the elastic laminate before layering the outer material, so that the additional stretching steps after layering described herein can be omitted.

In yet another suitable embodiment, the outer material can be thermally bonded to the molten thermoplastic elastomeric film / plastic laminate. In one embodiment, the binder is adjacent to the film extruder so that the outer material is contacted and bonded to the thermoplastic elastomeric film in the molten state as the film enters the extruder.

In alternative embodiments, the thermoplastic elastomeric film layer and the plastic layer are coextruded together, and the outer material with or without embossing can be laminated onto the thermoplastic elastomer film layer by heat sealing, adhesive bonding, or chemical bonding. Typically, the bonding strength between the outer coating material and the thermoplastic elastomeric film layer should be sufficient to avoid delamination, as is known in the art.

More specifically, in one embodiment, the outer material and the thermoplastic elastomeric film are thermally bonded together, as is known from the layering field. For example, in some embodiments, the outer material and the thermoplastic elastomeric film are thermally bonded using patterned pinch rolls to temperatures in the range of about 100 ° C to about 350 ° C, including from about 120 ° C to about 180 ° C, using load clamping forces from about 1000 N / m to about 20,000 N / m (about 6-112 pounds per linear inch) and using surface clamping speeds from about 5 m / min to about 500 m / min, includingfrom about 20 m / min to about 200 m / min. In suitable embodiments, when embossing the outer material, the patterned pinch shafts include a pattern that is smaller in scale than the embossing pattern used with uniformly pre-weakened outer coating material.

In other embodiments, the outer material and the thermoplastic elastomeric film are chemically bonded together, such as, for example, by using an adhesive composition. For example, the outer material and the thermoplastic elastomeric film can be adhesive bonded using known adhesive compositions (e.g., hot-melt adhesive compositions) with added amounts in the range of about 1 g / m ² to about 20 g / m ² , including from about 2 g / m ² to about 15 g / m ² , including from about 4 g / m ² to about 8 g / m ² , using load clamping forces from about 1000 N / m to about 20,000 N / m ( approximately 6-112 psi) and using surface clamping speeds from about 5 m / min to about 500 m / min, including from about 20 m / min to about 200 m / min.

In some embodiments, the adhesive composition is first applied to a thermoplastic elastomeric film before contacting and bonding the thermoplastic elastomeric film to the outer material.

In still other embodiments, the outer material and the thermoplastic elastomeric film are bonded together under pressure. Typically, when bonded under pressure, the outer material is bonded to a thermoplastic elastomeric film under pressure immediately after extrusion of the film when the film is still in a molten state. The setting of the clamping by the shaft to bind the external material to the molten elastomeric film under pressure can be achieved either by using the fixed clamping gap or by controlling the clamping force. In the first case, if the height or depth of the pin of the shaft (s) with the pattern is similar to the thickness of the outer coating layer, which is measured with an adjustable load of 364 kg / m ² (235 grams per square inch), the nominal clearance is from about 60% to 100% film thickness. For example, when layering 14 g / m ^{2 of} cellulose layer on one side of a film with a base weight of 130 g / m ² , the nominal thickness of the cellulosic material and film is approximately 0.089 mm and 0.120 mm, respectively, and the wire mesh has a wire spacing of 0.282 mm and a diameter a wire of 0.089 mm, the gap between two shafts with a wire mesh mounted on the surface is from about 0.090 mm to 0.100 mm, which is from about 75% to 85% of the film thickness is 0.120 mm. To set the control of the clamping force, it is expected that the clamping force is in the range from 1000 N / m to 20,000 N / m, similar to the clamping force required in the case of heat sealing.

After obtaining an elastic laminate by bonding the outer material with a thermoplastic elastomeric film, the outer material can be weakened by wetting the elastic laminate to the extent that the outer coating layer (s) contains (at) 30-150% moisture, or preferably 50% -80% moisture, and stretching the wetted elastic laminate as described above in one or both of the MD or CD until elongation of at least 50%, at least 100%, at least 150%, or even 200% or more . More specifically, the laminate is stretched from about 100% to about 600%, including from about 200% to about 500% of its normal state. After stretching, the elastic layered material is relaxed back to its normal state or close to it.

By the method of stretching / relaxing the laminate, the plastic layer of the laminate is elongated during the initial stretching and then corrugated when the elastomeric film is relaxed. Since the plastic layer is corrugated during the initial stretching and relaxation of the laminate, the modulus and tensile stress of the laminate mainly predominate in the elastomeric film layer, while maintaining sufficient elasticity as well as low tensile stress until it stretches to the stretching range at which the corrugated the plastic layer becomes flat.

As noted above, immediately after the elongation of the plastic layer, exceeding its level of deformation during initial tension, an increased tensile strength is formed due to the orientation of the molecules and hardening during tension of the plastic layer. In particular, it was found that the elastic layered materials according to the present disclosure have a final tensile strength of 50-100% more, or even 100-200% more, than a thermoplastic elastomeric film used separately.

In addition, with the initial stretching and relaxation of the elastic laminate, the strain-strain curve can shift to a lower strain region, for example, as shown in FIG. one.

When weakening the outer material by wetting the laminate, the laminate should be dried after stretching and relaxing. Drying of the laminate can be accomplished by any drying means known in the art, including evaporation or drying with air using an air dryer or a nozzle blow dryer. Typically, the dried elastic laminate will have less than 10% by weight of moisture, including less than 5% by weight of moisture and including less than 2% by weight of moisture.

From the detailed description of this disclosure, it will be apparent that modifications and variations are possible without departing from the scope of this disclosure as defined in the attached claims.

EXAMPLES

The following non-limiting examples are provided to further illustrate the present disclosure.

EXAMPLE 1

In this example, multilayer elastic layered materials were obtained containing a plastic layer located between two layers of a thermoplastic elastomeric film with an outer material.

In particular, a three-layer configuration of layered materials with an outer material was obtained using a coextrusion system with a three-layer feed unit. To obtain the outer layers of the thermoplastic elastomeric film, resins were mixed in a dry form, including VISTAMAXX ™ 6102FL, available from Exxon Mobil, Houston, Texas; and Kraton MD6716, available from Kraton Polymers, Houston, Texas, 70% and 30%, respectively. The resulting mixture was loaded into a 1.5 ”Trinity II Killion extruder (Killion Industries, Vista, CA) with a temperature profile set to 185-200 ° C. At the same time, plastic layers with an inner core were obtained by loading one of Dowlex 2045, a linear low-density polyethylene from Dow Chemical, Midland, Michigan, or Exact 3132, an ethylene-based hexane plastomer from Exxon Mobil, Houston, Texas, into a 1.25 ”B Killion extruder ( Killion Industries, Vista, CA) with a temperature profile of 170-200 ° C. Three-layer molten polymers were coextruded through a 20-inch extrusion die to obtain a base film weight of 30-100 g / m ² . Immediately after the formation of elastic laminates of the head, 8-14 g / m ² fabric 8 g / m ² meltblown webs, 10-18 g / m ² spunbond webs, 8 g / m ² web of spunbond-meltblown-spunbond (SMS) or 20 g / m ^{2 of} bonded carded web (BCW) was applied to the upper and lower sides of the layers of elastomeric film, and then passed together through a clip formed between two shafts that have a pin pattern with 85 X 85 pins per square inch, sec obtaining layered materials. To activate the layered materials in order to improve elasticity, the resulting layered materials were loaded into a grooved roller system with grooves separated by a distance of 0.130 inches between centers and a grip depth of 0.150-0.250 inches at a speed of approximately 50 feet per minute. Layered materials in this example are shown in table 1.

Table 1. Examples of laminated materials of a multilayer film (configuration elastic material / plastic / elastic material) with various external coatings.

EXAMPLE 2

In this example, multilayer elastic layered materials were obtained containing a plastic layer attached to a layer of a thermoplastic elastomeric film with an outer material.

In particular, a two-layer configuration of layered materials with an outer material was obtained using a co-extrusion system with a two-layer feed unit. To obtain a layer of thermoplastic elastomeric film, resins were mixed in a dry form, including VISTAMAXX ™ 6102FL, available from Exxon Mobil, Houston, Texas; and Kraton MD6716, available from Kraton Polymers, Houston, Texas, 70% and 30%, respectively. The resulting mixture was loaded into a 1.5 ”Trinity II Killion extruder (Killion Industries, Vista, CA) with a temperature profile set to 185-200 ° C. At the same time, plastic layers were obtained by loading one of Dowlex 2045, a linear low-density polyethylene from Dow Chemical, Midland, Michigan, or Exact 3132, an ethylene-based hexane plastomer from Exxon Mobil, Houston, Texas, into a 1.25 ”B Killion extruder (Killion Industries, Vista, California) with a temperature profile of 170-200 ° C. The bilayer molten polymers were coextruded through a 20-inch extrusion die to obtain a base film weight of 23-100 g / m ² . Immediately after the formation of a multilayer elastic film from the head, 8-14 g / m ² fabric, 8 g / m ² meltblown webs, 10 g / m ² spunbond webs, 8 g / m ² SMS webs or 20 g / m ² BCW webs to the side of the elastomeric film layer, and then passed together through a clip formed between two shafts that have a pin pattern with 85 × 85 pins per square inch to form laminate materials. To activate the layered materials in order to obtain elasticity, the resulting layered materials were loaded into a grooved roller system with grooves separated by a distance of 0.130 inches between centers, an engagement depth of 0.150-0.250 inches at a speed of approximately 50 feet per minute. Layered materials in this example are shown in table 2.

Table 2. Examples of laminated materials of a multilayer film (configuration elastic material / plastic) with various external coatings.

EXAMPLE 3

In this example, various thermoplastic elastomeric laminate materials were obtained that were evaluated for physical properties, including elongation at break and irreversible deformation after 150% elongation, and then compared with single-layer elastomeric films.

Single-layer elastomeric films were prepared using a 1.5 ”Trinity II Killion extruder (Killion Industries, Vista, CA). Vistamaxx 6102FL, available from Exxon Mobil, Houston, Texas; and Kraton MD6716, available from Kraton Polymers, Houston, Texas, was mixed dry, 70% and 30%, respectively, and loaded into an extruder with a temperature profile set to 185-200 ° C. The molten polymer was then loaded into a 20-inch extrusion die to form a film with a base weight of 60-100 g / m ² . Immediately after the formation of a single-layer elastic film from the head, 8-14 g / m ^{2 of the} outer coating of fabric was applied to the upper and lower sides of the layer of elastomeric film, and then passed together through a clip formed between shafts that have a pin pattern with 85 × 85 pins per square inch to produce layered materials. To activate layered materials in order to obtain elasticity and uniform tearing of the fabric layer, the resulting layered materials were loaded into a grooved roller system with grooves separated by a distance of 0.130 inches between centers and a grip depth of 0.150-0.250 inches at a speed of approximately 50 feet per minute.

Laminate based on a multilayer film with an outer coating of meltblown was obtained as described in Example 1. Physical properties measured using the method described above are shown in Table 3. Although the multilayer elastic laminate has a lower base weight than that of one layer of film, the maximum load at break is 20% higher than that of a layered material with one layer of film. Given a similar base weight of the film layer, the tensile strength of the multilayer elastic laminate will exhibit at least 2600 gf, which is almost 35% higher than that of a laminate based on a single layer film. In this case, multilayer elastic layered materials are characterized by a shorter elongation at break, which is characterized by lower ultimate tensile strength, with sufficiently good elasticity compared to layered material based on a single-layer film.

Table 3. Physical properties Film composition Base film weight Outdoor coating Base weight of laminate Physical properties Outer layer (85%) Inner layer (15%) Maximum load Elongation at break Irreversible deformation after 100% elongation one 2 one (g / m ² ) (g / m ² ) (g / m ² ) (gf) (%) (%) Vistamaxx 6102FL (70%) Kraton MD6716
(thirty%) Dowlex 2045 (100%) 80 Meltblown (8) 96 2085 718 12.6 Vistamaxx 6102FL (70%) Kraton MD6716 (30%) - one hundred Fabric (14) 128 1655 965 5,4

Claims (27)

1. A multilayer elastic layered material containing: the first layer of thermoplastic elastomeric film, characterized by irreversible deformation of less than 40% after 150% elongation, while the thermoplastic elastomeric film contains a polyolefin-based thermoplastic elastomer and a styrene block copolymer; a first plastic layer attached to the first surface of the thermoplastic elastomeric film layer, wherein the plastic layer is characterized by irreversible deformation of at least 50% higher than the irreversible deformation of the elastomeric film layer, and outer material attached to the second surface of the thermoplastic elastomeric film layer. 2. The elastic laminate according to claim 1, wherein the polyolefin-based thermoplastic elastomer contains an α-olefin homopolymer or copolymer with 1-12 carbon atoms. 3. The elastic laminate according to claim 1, wherein the styrene block copolymer is selected from the group consisting of styrene-ethylene propylene-styrene (SEPS), styrene-ethylene propylene-styrene-ethylenepropylene (SEPSEP), styrene-ethylenebutylene-styrene (SEBS), styrene ethylene-butylene-styrene-ethylene-butylene (SEBSEB), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-isoprene-butadiene-styrene (SIBS), styrene-ethylene-ethylene-propylene-styrene (SEPS) hydrogenated vinyl polyisoprene / hydrogenated polyisoprene / polystyrene; and combinations thereof. 4. The elastic laminate according to claim 1, wherein the first layer of the thermoplastic elastomeric film further comprises a strength improver, where the strength enhancer is an inorganic clay. 5. The elastic laminate according to claim 4, wherein the thermoplastic elastomeric film layer contains more than 50% by weight of a polyolefin-based thermoplastic elastomer, from about 15% by weight to about 40% by weight of a styrene block copolymer and from about 2% by weight up to about 10% by weight of a strength improver. 6. The elastic laminate according to claim 1, wherein the thermoplastic elastomeric film layer is substantially free of calcium carbonate. 7. The elastic laminate according to claim 1, wherein the plastic layer contains one of a semi-crystalline and amorphous polymer. 8. The elastic laminate according to claim 7, wherein the semi-crystalline or amorphous polymer is selected from the group consisting of polyolefins, polyolefin-based copolymers, polyesters, and combinations thereof. 9. The elastic laminate of claim 7, wherein the plastic layer contains from about 5% by weight to about 50% by weight of a semi-crystalline or amorphous polymer. 10. The elastic laminate according to claim 1, wherein the outer material is a nonwoven material selected from the group consisting of a knitted carded web, an aerodynamic canvas forming web, a conform web, a water-jet bonded web, a meltblown web, a spunbonded web, and combinations thereof . 11. The elastic laminate according to claim 1, wherein the outer material is a weakened cellulosic material. 12. A method for producing an elastic laminate, the method comprising: coextruding at least one layer of a thermoplastic elastomeric film with at least one plastic layer on a first surface of at least one layer of a thermoplastic elastomeric film and layering at least one outer material on the second surface of at least one layer of a thermoplastic elastomeric film to produce an elastic laminate, wherein the first layer of the thermoplastic film is characterized by irreversible deformation of less than 40% after 150% elongation and contains a polyolefin-based thermoplastic elastomer and a styrene block a copolymer, wherein the plastic layer is characterized by irreversible deformation of at least 50% higher than the irreversible deformation of the layer of elastomeric film, and When this plastic layer comprises one of a semicrystalline or amorphous polymer; stretching the elastic laminate in one or both of the machine direction or the transverse direction and relaxation of stretched elastic laminate. 13. The method according to p. 12, where the first layer of the thermoplastic elastomeric film further comprises a means of increasing strength, where the means of increasing strength is an inorganic clay. 14. The method of claim 13, wherein the thermoplastic elastomeric film layer contains more than 50% by weight of a polyolefin-based thermoplastic elastomer, from about 15% by weight to about 40% by weight of a styrene block copolymer, and from about 2% by weight to about 10% by weight of a strength improver. 15. The method according to p. 12, where the outer material is a cellulosic material. 16. The method according to p. 15, where the cellulosic material is embossed. 17. The method according to p. 12, where the outer material is a non-woven material selected from the group comprising a knitted carded web, a web obtained by aerodynamic canvas forming, a web of conforms, a web obtained by water-jet bonding, a meltblown web, a spunbond web, and combinations thereof. 18. The method of claim 12, wherein the semi-crystalline or amorphous polymer is selected from the group consisting of polyolefins, polyolefin-based copolymers, polyesters, and combinations thereof. 19. The method according to p. 18, where the plastic layer contains from about 5% by weight to about 50% by weight of a semi-crystalline or amorphous polymer. 20. The method according to p. 12, where the elastomeric laminate is stretched from about 100% to about 600% in the machine direction or in the transverse direction.

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